Building panels

ABSTRACT

A building or insulating panel ( 30 ) including a collapsible frame of generally square or rectangular configuration, which is collapsible between a generally flat condition and an erected condition in which it is installed. The frame including overlying top and bottom sheets ( 31,32 ) that are generally parallel and spaced apart in the erected condition of the frame by two webs ( 33,36 ) which are spaced apart to extend in generally parallel realationship lengthwise along opposite side regions of the frame. The webs ( 33, 36 ) extend substantially perpendicular to the top and bottom sheets ( 31, 32 ) in the erected condition and are disposed substantially parallel to the top and bottom sheets ( 31, 32 ) in the collapsed condition. The panel further includes reinforcing means ( 37 ) which is inserted between the top and bottom sheets ( 31, 32 ) when the frame is in the erected condition to reinforce the panel ( 30 ) against collapse. The insulating panel may have an intermediate sheet disposed between the top and bottom sheets which is adhesively connected to each of the top and bottom sheets. The intermediate sheet is formed as a corrugated sheet and at least one of the top and bottom sheets and the intermediate sheet are formed from reflective insulating foil to create a reflective air space.

This application is the national phase under 35 U.S.C. § 371 of PCTInternational Application No. PCT/AU01/00467 which has an Internationalfiling date of Apr. 24, 2001, which designated the United States ofAmerica.

The present invention relates to building panels and to a method andarrangement of installing building panels. The present invention wasdeveloped in relation to insulating batts and particularly, although notexclusively, to the construction and installation of insulating battsformed from self-supporting sheets of reflective insulating material. Itwill therefore be convenient to describe the invention in relation tothat style of insulating batt, although it is to be appreciated, thatthe invention could apply to non-insulating panels and to insulatingbatts formed differently to or from alternative material to thatdescribed above.

Australian Patents Nos. 511833 and 647948 disclose insulating battshaving substantially flat, self-supporting sheets of reflectiveinsulating material secured in substantially parallel, overlyingrelationship. The sheets of those batts are secured relative to eachother by parallel webs of sheet material that permit the batt to beadjusted between a collapsed condition to an erected condition.Advantageously, these batts have very little volume when collapsed andcan be stored and transported in that condition, for erection on sitewhen being installed generally in a roof of a building.

The installation of the above kinds of insulation batts is not alwayssimple, particularly in relation to commercial buildings, such aswarehouses and factories. In those buildings, it is preferable to fitthe insulating batts between adjacent purlins and until recently, asuitable method for such installation, which is both simple andeffective in respect of the insulation provided, has been unavailable.

According to the present invention there is provided a building panelincluding a collapsible frame of generally square or rectangularconfiguration, which is collapsible between a generally flat condition,and an erected condition in which it is installed, said frame includingtop and bottom sheets that are generally parallel and spaced apart insaid erected condition of said frame by two webs which are spaced apartto extend in generally parallel relationship lengthwise along oppositeside regions of said frame, said webs extending substantiallyperpendicular to said top and bottom sheets in said erected conditionand being disposed substantially parallel to said top and bottom sheetsin said collapsed condition, said panel further including reinforcingmeans which is inserted between said top and bottom sheets when saidframe is in said erected condition to reinforce said panel againstcollapse.

The present invention further provides a method of installing a buildingpanel having a collapsible frame of generally square or rectangularconfiguration, which is collapsible between a generally flat condition,and an erected condition, said frame including top and bottom sheetsthat are generally parallel and spaced apart in said erected conditionof said frame by two webs which are spaced apart to extend in generallyparallel relationship lengthwise along opposite side regions of saidframe, said webs extending substantially perpendicular to said top andbottom sheets in said erected condition and being disposed substantiallyparallel to said top and bottom sheets in said collapsed condition, saidmethod including transporting said frame to an installation site in saidcollapsed condition, expanding said frame to said erected condition,inserting reinforcing means between said top and bottom layers of saidframe and thereafter placing said panel in position.

The reinforcing means can be of sheet form which is collapsible betweena substantially flat condition for transport and an erected conditionfor installation of the insulating batt, or it can be formed as a memberready for assembly in the frame in a nestable condition in which aplurality of reinforcing means can be nested together for transport tothe installation site. In either case, the advantages of the inventionis realised by the compact nature of the reinforcing means for transportand production and the simple nature of the assembly process. In eithercase, the reinforcing means is insertable in the erect condition thereofinto the space of the erected frame, where after the insulating batt canbe installed.

The invention advantageously is comprised of a collapsible frame andcollapsible or nestable reinforcing means each of which can be handledand transported to the site of insulation with substantially reducedbulk compared to the erected condition of the panel or batt. Thus, thecomponents of the insulating batt can be easily handled and transportedat minimum cost and are simple to erect and thereafter be installed.This compares with alternative batt structures which are bulky and moredifficult to install.

The reinforcing means can be in the form of a corrugated sheet whichincludes successive oppositely facing peaks extending in contact witheach of the top and bottom sheets of the frame for supporting thosesheets in a spaced apart disposition. The corrugations could be of acurved configuration, taking a cross-sectional profile similar to a sinewave, or it may have a concertina-like or sawtooth profile which iscomprised of a plurality of substantially planar segments disposed atopposite inclined angles, so as to define a succession of adjacent peaksand troughs, with the apex of each peak and trough being in engagementwith either the top or bottom sheet of the frame. The strength of thepanel or batt when assembled relies partly on the frictional contactbetween the reinforcing means and the top and bottom sheets of theframe. Thus, a sine wave configuration provides better strength than thesawtooth profile, because the former has greater surface area contactthan the edge contact of the latter. An advantage of the presentinvention is that the reinforcing means need not be fixed within theframe, such as by an adhesive, but can be simply placed or inserted intothe frame. This provides for simple assembly which is a feature of thepresent invention.

The required spacing of the webs is dependent on the grade of papernormally used for construction of the panel or insulating batt. Thus,the use of a heavy paper grade can reduce the need for additional websbetween the side edge webs. The reinforcing means and the webs bothcontribute to the stiffness of the panel or batt and the choice of thematerial of one can influence the material choice for the other.

It will be appreciated, that the above examples show that thereinforcing means could take a variety of forms. Thus, the form of thereinforcing means is not necessarily critical, but instead what isimportant, is that the reinforcing means be nestable or alternativelycollapsible, so that it may be transported to the insulation site eitherin a nested or substantially flat form so having the same transport andhandling advantages as the frame.

In one arrangement, the frame includes three or more webs extendingbetween the top and bottom sheets of the frame, so dividing the spacebetween the top and bottom sheets into two or more smaller spacesegments. Therefore, the frame in this arrangement, includes a pair ofwebs disposed toward opposite side edge regions of the frame and atleast one further web disposed intermediate or midway between the twoedge webs. In a particularly preferred arrangement, a pair of webs aredisposed intermediate the side edge webs.

In the above arrangement, the reinforcing means is arranged to extendbetween adjacent webs. Thus, in the arrangement in which three webs aredisposed between the top and bottom sheets, the reinforcing means iscomprised of two separate reinforcing members or components. Thosemembers may be identical in profile or dissimilar as required.Alternatively, in the arrangement in which a pair of intermediate websis disposed between the side edge webs, three reinforcing members aredisposed between the top and bottom sheets of the frame.

In an alternative arrangement, reinforcing means may be disposed in onlyone of the space segments between adjacent frame webs. That is, in thearrangement in which two intermediate webs are disposed between the sideedge webs, thus defining three space segments, each of those spacesegments may accommodate reinforcing means, or alternatively only one ortwo of the space segments may accommodate such reinforcing means. Therequirement for reinforcing means will depend on the rigidity of theinsulating batt which is required.

For example, in the above arrangement in which three space segments areformed, the insulating characteristics of the insulating batt may onlyrequire reinforcing means in one of the space segments, and that willfacilitate a reduction in the overall cost of the insulating batts.Alternatively, if the insulating batt has a length or width of suchdimensions that require each of the space segments to accommodatereinforcing means, then such means can easily be included. Therefore,the insulating batt of the invention is flexible in its requirement forreinforcing means, depending on the insulating characteristics required,and the structural requirements.

A batt of the above described kind provides general advantages inrelation to storage and transport, because it can be stored and shippedin a collapsed form. It further provides advantages in production,because it is very easy to manufacture, assemble and install. The panelof the invention is particularly suited to installation in ceilings, inparticular so-called suspended T-bar ceilings generally found incommercial office space. The panel can replace presently used acousticor plasterboard tiles at a much lower cost. Additionally, the panel canbe formed as an insulating batt, which further enhances its use as aceiling panel.

The use of reflective insulating foil provides a particular advantage ofthe present invention over acoustic and plasterboard panels nowemployed, in that reflective foil is waterproof. Accordingly, ceiling orwall leakage will not necessarily destroy or affect the performance ofthe panel as it may with non-waterproof panels, which include theaforementioned acoustic and plasterboard kind. This advantage of thepresent invention extends to installation sites in regions of highhumidity also, such that a panel of the invention, formed fully orpartly from reflective insulating foil, may be preferred in suchregions.

According to the present invention, there is further provided aninsulating batt having top and bottom sheets and an intermediate sheetwhich is disposed between the top and bottom sheets and which isadhesively connected to each of those sheets, the intermediate sheetbeing formed as a corrugated sheet and at least one of the top andbottom sheets and the intermediate sheet being from reflectiveinsulating foil, to create a reflective air space.

The above insulating batt can be manufactured by applying the corrugatedintermediate sheet adhesively to one of the top and bottom sheets andthen adhesively applying the other of the top and bottom sheets to theintermediate sheet. Like the earlier described batt, this batt is simpleto manufacture and install and, as it is envisaged that it would havingindustry acceptable insulating characteristics in an overall thicknessof about 25 mm, it would also be attractive for storage, transport andinstallation.

An insulating batt according the invention is suitable for insulating avariety of structures, such as wall and roof structures. The insulatingbatts of the invention can be installed in a progressive manner, byinstalling an insulating batt between adjacent purlins and pushing thatbatt along the length of the purlins with successive batts. The battsaccording to the invention can be fixed to the purlins in any suitablemanner or they may simply rest under their own weight without sagging,by employment of the reinforcing means.

The attached drawings show example embodiments of the invention of theforegoing kind. The particularity of those drawings and the associateddescription does not supersede the generality of the preceding broaddescription of the invention.

FIG. 1 shows an insulating batt 30 which includes a frame having top andbottom layers 31 and 32 respectively which are generally rectangular anddisposed in parallel, overlying relationship. The top and bottom layersmay be made of a double-sided foil laminate which in its planar form, isrelatively flexible, although the invention is not restricted to such amaterial and alternative materials may be employed. Materials such asthose described in Australian patents 511833 and 647948 are suitable foruse in the construction of the insulating batt 30.

The frame of the insulating batt 30 further comprises a plurality ofwebs 33 to 36 which are disposed to extend lengthwise of the batt 30 andsubstantially at right angles to the top and bottom layers 31 and 32.The webs 33 to 36 can pivot relative to the top and bottom layers 31 and32, to permit the batt 30 to collapse from the erected condition shownin FIG. 1 to a collapsed condition, in which the webs are substantiallyparallel to the layers 31 and 32. Thus, the webs are connected to thetop and bottom layers 31 and 32 in a manner to permit such pivotingmovement and such an arrangement or construction is disclosed in theaforementioned Australian patents. Therefore, that construction can beemployed in an insulating batt according to the invention, oralternative constructions can be employed that permit the samecollapsible movement.

The insulating batt 30 of FIG. 1 includes four webs as shown. However,the invention is only required to include webs 33 and 36 disposed alongthe side edges of the frame of the batt 30. The intermediate webs 34 and35 can be provided as required to suit the necessary structuralcharacteristics of the batt 30.

Between each of the webs illustrated in FIG. 1, is reinforcing means inthe form of corrugated insulating sheet reinforcing components 37 to 39.Each of the members 37 to 39 is formed with a plurality of inclinedplanar sections as shown, which meet to form adjacent oppositelypointing apexes in contact respectively with the inside surfaces of thetop and bottom sheets 31 and 32. The reinforcing members 37 to 39 alsoextend into contact with the webs 33 to 36. The reinforcing members 37to 39 support the frame of the insulating batt 30 lengthwise againstsagging. Thus, the batt 30 has considerable rigidity in the longitudinaldirection L so that the batt 30 can be made to span greater distancesthan would otherwise be possible without the members 37 to 39.Additionally, the use of an insulating sheet as a medium for thereinforcing members 37 to 39 facilitates better insulating performancethan in absence of those sheets. Thus, the corrugated insulatingreinforcing members 37 to 39 have a dual function.

The insulating batt 30 is advantageously collapsible, by removal of thecorrugated reinforcing members 37 to 39 where after the frame of thebatt 30 can be collapsed to a flat condition. FIG. 1 a shows theinsulating batt 30 in a collapsed condition, with the reinforcingmembers 37 to 39 removed. The members 37 to 39 can be nested together.Thus, at the site of installation, it is a simple matter of erecting theframe of the batt 30, and inserting the reinforcing members 37 to 39into the space segments 40 to 42 between the top and bottom layers 31and 32, after which the batt is ready for installation.

FIG. 2 shows an alternative insulating batt 50 which has somecharacteristics of the insulating batt 30 of FIG. 1 and therefore likeparts will have the same reference numeral plus 100. The batt 50 howeverdiffers from the batt 30, by way of the addition of a second layer suchthat the batt 50 includes a bottom layer 132, and intermediate layer 51and a top layer 52. Such a batt can be manufactured according to themethods disclosed in Australian patent nos. 511833 and 647948. Thus, thebatt 50 includes webs 53 to 56 extending between the intermediate layer51 and the top layer 52. The webs 53 and 56 may be continuations of thewebs 133 to 136, although manufacturing limitations are likely torequire that the webs 54 and 55 be separately formed from the webs 134and 135.

In the arrangement shown in FIG. 2, reinforcing members 137, 138 and 139are disposed in the space segments 140, 141 and 142. No reinforcingmembers are disposed in the spaces 56 to 58, although if requiredreinforcing members could be inserted in these spaces. Thus, theinsulating batt 50 illustrates the flexibility that the presentinvention provides. For example, if further reinforcement was required,reinforcing members could be included in only one of the space segments56 to 58, or in two or in each of those space segments. Thus, if theinsulating characteristics of the batt 50 were required to be higherthan that achievable by the arrangement illustrated in FIG. 2, then theaddition of further corrugated reinforcing members disposed in one ormore of the space segments 56, 57 and 58 may achieve those requirements.

FIG. 2 illustrates the flexibility that the present invention canprovide. The invention can therefore be applied for example, to a fourlayer insulating batt and the reinforcing members can be applied to eachor any selection of the space segments within the batt as consideredappropriate. The reinforcing members can be made of any suitablematerial and could for example be made of cardboard or stiff paper ifthe requirement of the reinforcing members was to provide rigidity onlyand little if no insulating characteristics. In the preferredarrangement however, the reinforcing members are constructed out of thesame material as the frame of the insulating batt so as to enhance theinsulating capability of each batt.

FIG. 3 illustrates a further alternative insulating batt 60, which,similar to the batt 30 of FIG. 1, has top and bottom layers 61 and 62and webs 63 and 64. The batt 60 is collapsible in the manner of the batt30 and in the form illustrated, the batt 60 is erect and includescorrugated reinforcing means 65 which is of generally curved form. Thereinforcing means 65 has the reinforcing function of the reinforcingmembers 37 to 39 of the batt 30 and is removably insertable between thetop and bottom layers 61 and 62.

The invention described herein is susceptible to variations,modifications and/or additions other than those specifically describedand it is to be understood that the invention includes all suchvariations, modifications and/or additions which fall within the spiritand scope of the above description.

1. A method of assembling a building panel, the method comprising thesteps of: providing a collapsible frame of generally square orrectangular configuration, which is collapsible between a generally flatcondition, and an erected condition, said frame including overlying topand bottom sheets that are generally parallel and spaced apart in saiderected condition of said frame by two webs which are spaced apart toextend in generally parallel relationship lengthwise along opposite sideregions of said frame, said webs extending substantially perpendicularto said top and bottom sheets in said erected condition and beingdisposed substantially parallel to said top and bottom sheets in saidcollapsed condition, expanding said frame to said erected condition andthereafter inserting reinforcing means between said top and bottomsheets, the reinforcing means and the wens extending lengthwise alongentire lengths of the opposite side regions of said frame; and placingsaid erected building panel in an installed position in a building.
 2. Amethod according to claim 1, said reinforcing means being of sheet formand being collapsible between a generally flat condition and an erectedcondition, said reinforcing means being formed into said erectedcondition for insertion between said top and bottom sheets of saidframe.
 3. A method according to claim 1, said reinforcing means beingformed as a member which is shaped ready for insertion between said topand bottom sheets of said frame, said shape of said reinforcing memberbeing such as to permit nesting between a plurality of said reinforcingmembers.
 4. A method according to claim 1, said reinforcing means havinga corrugated form for insertion into said frame, said corrugated formdefining successive oppositely facing peaks respectively extending intocontact with said top and bottom sheets of said frame.
 5. A methodaccording to claim 4, said corrugated form being of generally curvedform.
 6. A method according to claim 4, said corrugated form comprisinga generally sawtooth profile.
 7. A method according to claim 4, saidreinforcing means being arranged to engage said webs.
 8. A methodaccording to claim 1, said panel including at least a further webdisposed between said webs at said opposite side regions of said frameand extending generally parallel thereto and substantially perpendicularto said top and bottom sheets in said erected condition of said frameand being disposed substantially parallel to said top and bottom sheetsin said collapsed condition of said frame, said reinforcing means beingprovided between at least one pair of adjacent webs.
 9. A methodaccording to claim 8, wherein said at least a further web is a singlefurther web.
 10. A method according to claim 9, wherein said further webis disposed substantially midway between said webs at said opposite sideregions.
 11. A method according to claim 8, including a pair of furtherwebs.
 12. A method according to claim 1, said frame including anintermediate sheet disposed intermediate and substantially parallel tosaid top and bottom layers and having plan dimensions substantially thesame thereas and said webs being arranged to support said top and bottomsheets and said intermediate sheet in spaced apart relationship.
 13. Amethod according to claim 1, said top and bottom sheets and said websbeing formed of cardboard or cardboard-like material.
 14. A methodaccording to claim 1, said panel being formed as an insulating batt, inwhich said top and bottom layers are formed from reflective insulatingmaterial.
 15. A method according to claim 14, wherein said reinforcingmeans is formed from reflective insulating material.
 16. A panel madeaccording to the method of claim
 1. 17. A method of installing abuilding panel, the method comprising: providing a collapsible frame ofgenerally square or rectangular configuration, which is collapsiblebetween a generally flat condition, and an erected condition, said frameincluding overlying top and bottom sheets that are generally paralleland spaced apart in said erected condition of said frame by two webswhich are spaced apart to extend in generally parallel relationshiplengthwise along opposite side regions of said frame, said websextending substantially perpendicular to said top and bottom sheets insaid erected condition and being disposed substantially parallel to saidtop and bottom sheets in said collapsed condition; and as a first step,either of 1-transporting said frame to an installation site, or2-expanding said frame to said erected condition and thereafterinserting reinforcing means between said top and bottom layers of saidframe, the reinforcing means and the webs extending lengthwise alongentire lengths of the opposite side regions of said frame thenconducting the other of these steps and thereafter placing said erectedbuilding panel in an installed position in a building.
 18. A methodaccording to claim 17, wherein said transportation step is the firststep conducted and for that step, said frame is transported in saidcollapsed condition.
 19. A method according to claim 17, saidreinforcing means being collapsible between a generally flat conditionand an erected condition, said method including transporting saidreinforcing means in said flat condition to said installation site andthereafter expanding said reinforcing means to said erected conditionprior to insertion thereof into said frame.
 20. A method according toclaim 17, said reinforcing means being formed as a member which isnestable with other reinforcing members and said method includingtransporting a plurality of said reinforcing members to saidinstallation site in a nested condition.
 21. A method according to claim17, said panel being an insulating batt.
 22. A panel made according tothe method of claim 17.